System for varying coffee intensity

ABSTRACT

A coffee pod with varying intensity. The coffee pod includes a substantially rigid sidewall, a substantially rigid base, and coffee grinds positioned therein. More than about seventy percent (70%) of the coffee grinds may include a particle size distribution of between about 200 to about 300 microns. The coffee grinds may have a weight of the about five (5) to about eight (8) grams.

RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 10/908,350, filed on May 9, 2005, which in turn isa continuation-in-part of U.S. patent application Ser. No. 10/604,445,filed on Jul. 22, 2003, now U.S. Pat. No. 6,948,420.

TECHNICAL FIELD

The present invention relates generally to a container for brewingmaterial and more particularly relates to a pod for use in the automaticbrewing of coffee, tea, and other beverages.

BACKGROUND OF THE INVENTION

Various types of automatic coffee and tea dispensers are known.Generally described, these dispensers hold a measure of ground coffee,tealeaves, or other type of brewable material in a container of somesort. Hot water typically is added to the material so as to brew thebeverage. The material is usually held in some sort of disposablecontainer that must be opened or penetrated so as to allow the hot waterto pass therethrough.

One drawback with these known brewing devices is that the elements ofthe device that come into contact with the brewing material usually mustbe cleaned. Further, the container for the material must be inserted andaligned in the dispenser for each beverage. As a result, the beveragedispenser as a whole may be somewhat slow between beverage cyclesbecause the container must be inserted, aligned, removed and/or thedispenser elements must be cleaned.

There is a desire, therefore, for a device that brews a beverage with aquick cycle time. The device preferably should be relatively inexpensiveand easy to use and produce a high quality beverage. Likewise, thedevice preferably should be adaptable for different types of brewingmaterials and amounts of brewing materials.

SUMMARY OF THE INVENTION

The present application thus describes a coffee pod. The coffee podincludes a substantially rigid sidewall, a substantially rigid base, andcoffee grinds positioned therein. More than about seventy percent (70%)of the coffee grinds may include a particle size distribution of betweenabout 200 to about 300 microns. The coffee grinds may have a weight ofthe about five (5) to about eight (8) grains.

About seventy-five to about eighty-five percent (75-85%) of the coffeegrinds may have a particle size distribution of about 250 microns. Up toabout 30% of the coffee grinds may include a particle size distributionof less than about 100 microns. The pod may produce about an eight (8)ounce beverage. About six (6) grams of the coffee grinds may be used fora low intensity beverage. About eight (8) grams of the coffee grinds maybe used for a high intensity beverage.

The present application further describes a method of preparing abeverage. The method includes the steps of grinding a number of coffeebeans such that more than about seventy percent (70%) of a resultantfirst coffee grinds may include a particle size distribution of betweenabout 200 to about 300 microns, placing the first coffee grinds in apod, varying the amount of the first coffee grinds so as to vary theintensity of the resultant beverage, and flowing water through the podso as to produce the resultant beverage.

About seventy-five to about eighty-five percent (75-85%) of the firstcoffee grinds may have a particle size distribution of about 250microns. The method further may include grinding the coffee beans suchthat no more than thirty percent (30%) of a resultant second coffeegrinds may include a particle size distribution of less than about 100microns and placing the second grinds in the pod. About six (6) grams ofthe first and the second coffee grinds result in a low intensitybeverage. About eight (8) grams of the first and the second coffeegrinds result in a high intensity beverage.

The present application further describes a brewable material pod. Thebrewable material pod may include a substantially rigid sidewall, asubstantially rigid base, and an amount of a brewable materialpositioned therein. More than about seventy percent (70%) of thebrewable material may include a particle size distribution of betweenabout 200 to about 300 microns. The brewable material may have a weightof the about five (5) to about eight (8) grams. The brewable materialmay include coffee grinds or tea leaves.

These and other features of the present invention will become apparentto one of ordinary skill in the art upon review of the followingdetailed description of the preferred embodiments when taken inconjunction with the drawings and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of one embodiment of a beverage dispensersystem for use with the present invention.

FIG. 2 is a top plan view of the beverage dispenser system of FIG. 1.

FIG. 3 is a perspective view of a turret system of the beveragedispenser system of FIG. 1.

FIG. 4 is a perspective view of an injector assembly of the beveragedispenser system of FIG. 1, with the guide wheels and the return springof the support plate shown in phantom lines.

FIG. 5 is a rear perspective view of the injector assembly of thebeverage dispenser system of FIG. 1, with the idler wheel and the limitswitch shown in a cut away view.

FIG. 6 is perspective view of a pod as described herein.

FIG. 7 is perspective view of a pod as described herein.

FIG. 8 is a side cross-sectional view of the pod of FIG. 6.

FIG. 9 is a top perspective view of the pod of FIG. 6.

FIG. 10 is a bottom perspective view of the pod of FIG. 6.

FIG. 11 is a side cross-sectional view of a pod showing the lid.

FIG. 12 is a side cross-sectional view of a pod cartridge with an amountof brewing material positioned therein.

FIG. 13 is a side plan view of an alternative embodiment of the lip ofthe pod of FIG. 6.

FIG. 14 is a side cross-sectional view of the pod of FIG. 13.

FIG. 15 is a side plan view of a grinder for use with the invention asdescribed herein.

FIG. 16 is a particle size distribution chart.

FIG. 17 is a particle size distribution chart.

DETAILED DESCRIPTION

Commonly owned U.S. Pat. No. 6,786,134, entitled “COFFEE AND TEADISPENSER” and U.S. patent application Ser. No. 10/604,445, entitled“COFFEE AND TEA POD”, now allowed (U.S. 2005-0016383 A1), areincorporated herein by reference.

Referring now to the drawings, in which like numerals refer to likeelements throughout the several views, FIGS. 1 and 2 show oneapplication of a beverage dispenser system 100. In these figures, a podbrewing apparatus 300 is shown. The pod brewing apparatus 300 mayinclude a heat exchanger 150 positioned within a hot water reservoir 160and in communication with an injection nozzle 200 as is shown. In thisembodiment, the elements of the beverage dispenser system 100 as a wholeare mounted onto a dispenser frame 305. The dispenser frame 305 may bemade out of stainless steel, aluminum, other types of metals, or othertypes of substantially noncorrosive materials.

The injection nozzle 200 may interact with one or more pod cartridges210 so as to produce the desired beverage in a cup 230 or any other typeof receptacle. The pod cartridges 210 may be positioned in the beveragedispenser system 100 within a turret assembly 310. The turret assembly310 may be fixedly attached to the dispenser frame 305. As is shown inFIG. 3, the turret assembly 310 may include a turret plate 320positioned within a turret frame 325. The turret frame 325 may be madeout of stainless steel, aluminum, other types of conventional metals, orsimilar types of substantially noncorrosive materials. The turret plate320 may be substantially circular or have any convenient shape. Theturret plate 320 may include a number of pod apertures 330. The podapertures 330 may be sized to accommodate the pod cartridges 210. Theturret plate 320 may spin about a turret pin 340. A turret motor 350 maydrive the turret assembly 310. The turret motor 350 may be aconventional AC motor or a similar type of device. The turret motor 350may drive the turret assembly 310 at about six (6) to about thirty (30)rpm, with about twenty-five (25) rpm preferred.

The turret plate 320 also may have a number of detents 360 positionedabout its periphery. The detents 360 may be positioned about each of theturret apertures 330. The detents 360 may cooperate with one or morelimit switches 365 so as to control the rotation of the turret plate320. The rotation of the plate 320 may be stopped when the limit switch360 encounters one of the detents 360. Rotation of the plate 320 may becontrolled by similar types of devices.

Positioned adjacent to the turret assembly 310 may be an injectorassembly 400. The injector assembly 310 may be fixedly attached to thedispenser frame 305. The injector assembly 400 also may include aninjector frame 410 extending above the turret assembly 310. The injectorframe 410 may be made out of stainless steel, other types of metals, orsimilar types of substantially noncorrosive materials.

Referring now to FIGS. 4 and 5, the injector assembly 400 may includethe injection nozzle 200 as described above with respect to FIG. 2. Theinjection nozzle 200 may have a narrow tip so as to penetrate the podcartridge 210 if needed or a wide mouth to accommodate the entire podcartridge 210. The injector assembly 400 may include an injector head420 that cooperates with the injection nozzle 200. The injector head 420may be slightly larger in diameter than the pod cartridges 210. Theinjector head 420 also may be made out of stainless steel, plastics, orsimilar types of substantially noncorrosive materials. The injector head420 may include a sealing ring positioned about its lower periphery. Thesealing ring may be made out of rubber, silicone, or other types ofelastic materials such that a substantially water tight seal may beformed between the injector head 420 and the pod cartridge 210. The heatexchanger 150 may be in communication with the injector head 420 so asto provide hot, pressurized water to the pod cartridges 210.

The injector head 420 may be moveable in a substantially vertical planevia a cam system 440. (The terms “vertical” and “horizontal” are used asa frame of reference as opposed to absolute positions. The injector head420 and the other elements described herein may operate in anyorientation.) A cam system drive motor 450 may drive the cam system 440.The drive motor 450 may be a conventional AC motor similar to the turretmotor 350 described above. The drive motor 450 also may be a shaded poleor a DC type motor. The drive motor 450 may rotate an eccentric cam 460via a drive belt system 470. The drive motor 450 and the gear system 470may rotate the eccentric cam 460 at about six (6) to about thirty (30)rpm, with about twenty-five (25) rpm preferred. The eccentric cam 460may be shaped such that its lower position may have a radius of about4.1 to about 4.8 centimeters (about 1.6 to 1.9 inches) while its upperposition may have a radius of about 3.5 to 4.1 centimeters (about 1.3 toabout 1.7 inches).

The eccentric cam 460 may cooperate with an idler wheel 480. The idlerwheel 480 may be in communication with and mounted within a supportplate 490. The support plate 490 may maneuver about the injector frame410. The support plate 490 may be made out of stainless steel, othertypes of steel, plastics, or other materials. The support plate 490 maybe fixedly attached to the injector head 420. The support plate 490 mayhave a number of guide wheels 500 positioned thereon such that thesupport plate 490 can move in the vertical direction within the injectorframe 410. A return spring 520 also may be attached to the support plateand the injector frame 410. A limit switch 530 may be positioned aboutthe cam 460 such that its rotation may not exceed a certain amount.

The injector head 420 thus may maneuver up and down in the verticaldirection via the cam system 440. Specifically, the drive motor 450 mayrotate the eccentric cam 460 via the gear system 470. As the eccentriccam 460 rotates with an ever-increasing radius, the idler wheel 480pushes the support plate 490 downward such that the injector head 420comes in contact with a pod cartridge 210. The eccentric cam 460 maylower the injector head 420 by about 6.4 to about 12.7 millimeters(about one-quarter to about one-half inch). Once the injector head 420comes into contact with the pod cartridge 210, the eccentric cam 460 maycontinue to rotate and increases the pressure on the pod cartridge 210until the cam 460 reaches the limit switch 530. The injector head 420may engage the pod cartridge 210 with a downward force of about 136 to160 kilograms (about 300 to 350 pounds). The sealing ring thus may forma substantially airtight and water tight seal about the pod cartridge210. The drive motor 450 may hold the cam 460 in place for apredetermined amount of time. The cam system 440 then may be reversedsuch that the injector head 420 returns to its original position.

Once the injection nozzle 200 of the injector head 420 is in contactwith the pod cartridge 210, the hot high-pressure water may flow fromthe heat exchanger 150 into the injector head 420. The pressure of thewater flowing through the pod cartridge 210 may vary with the nature ofthe brewing material 550 therein.

FIGS. 6-12 show an embodiment of the pod cartridge 210 that may be usedwith the beverage dispenser system 100 or other types of beveragesystems. In fact, the pod cartridge 210 may be used with any type ofmixable material, flavoring, additives, and other substances. The podcartridge 210 may be substantially in the shape of a cup 600. The cup600 may be made out of a conventional thermoplastic such as polystyrene,polyethylene, polypropylene and similar types of materials.Alternatively, stainless steel or other types of substantiallynon-corrosive materials also may be used. The cup 600 may besubstantially rigid so as to withstand the heat and pressure of the brewcycle without imparting any off-tastes. As described below, however, bythe term “rigid” we mean that the cup 600 may flex or deform slightlywhile under pressure.

The cup 600 may include a substantially circular sidewall 610 and asubstantially flat base 620. Other shapes also may be used. The sidewall610 and the base 620 of the cup 600 may be molded and form a unitaryelement or a separate sidewall 610 and a separate base 620 may befixably attached to each other. The sidewall 610 and the base 620, aswell as the cup 600 as a whole, may have any convenient diameter so asto accommodate the pod apertures 330 of the turret plate 320 of theturret assembly 310 and the injector head 420 of the injector 400.Alternatively, the sidewall 610 and the base 620 of the cup 600 may haveany convenient diameter so as to accommodate other types of beveragedispenser systems 100 or similar types of devices.

By way of example, the sidewall 610 may have an inside diameter of about39.3 millimeters (about 1.549 inches) with a wall thickness of about 1.1millimeters (about 0.043 inches). The sidewall 610 may have a slighttaper from the top to the bottom. Other sizes or dimensions may be usedas desired.

The cup 600 as a whole may have a variable depth depending upon theamount of brewing material intended to be used therein. In the case ofthe cup 600 intended to be used for about a 355 milliliter (about twelve(12) ounce) beverage, the cup 600 may have a total height of about 28.7millimeter (about 1.13 inches) and a useable inside height of about 17.1millimeters (about 0.674 inches). The height to diameter ratio for the355 milliliter cup 600 therefore may be about 0.73 for the total heightand about 0.435 for the usable inside height. The cup 600 may have about6.4 grams of a polypropylene material.

A cup 600 to be used with, for example, about a 237 milliliter (about aneight (8) ounce) beverage may have a height of about 22.5 millimeters(about 0.887 inches) and a usable inside height of about 11.8 millimeter(about 0.463 inches). The ratio thus may be about 0.57 for the totalheight and about 0.3 for the usable inside height. The cup 600 may haveabout 5.8 grams of a polypropylene material.

These ratios between diameter and depth provide the cup 600 and thecartridge 210 as a whole with sufficient strength and rigidity whileusing a minimal amount of material. The cartridge 210 as a whole mayhave about five (5) to about eight (8) grams of plastic material thereinwhen using, for example, a polypropylene homopolymer. As a result, thecup 600 and the cartridge 210 as a whole may withstand temperatures ofover about 93 degrees Celsius (about 200 degrees Fahrenheit) for up tosixty (60) seconds or more at a hydraulic pressure of over about ten(10) bar (about 150 pounds per square inch). Although the cup 600 havingthese ratios may flex or deform somewhat, the cup 600 and the cartridge210 as a whole should withstand the expected water pressure passingtherethough. These dimensions and characteristics are for the purpose ofexample only. The sidewall 610 and the base 620 of the cup 600 may takeany desired or convenient size or shape. For example, the sidewall 610may be straight, tapered, stepped, or curved if desired.

The base 620 may include a number of apertures 640 formed therein. Theapertures 640 may extend through the width of the base 620. Theapertures 640 may be largely circular in shape with a diameter each ofabout 1.6 millimeters (about 0.063 inches). Any desired shape or size,however, may be used. In this embodiment, about 54 apertures 640 areused herein, although any number may be used. The selected number andsize of apertures 640 provide the appropriate pressure drop when a cup600 of a given dimension is used.

The base 620 also may have a number of support ribs 650 positionedthereon. An inner circular rib 660, an outer circular rib 670, and anumber of radial ribs 680 may be used. In this embodiment, the ribs 650may have a depth of about one (1) millimeter (about 0.04 inches),although any desired thickness may be used. Likewise, any desired numberand/or shape of the ribs 650 may be used. The design of the ribs 650also provides increased support and stability to the cartridge 210 as awhole with a minimum amount of material.

The sidewall 610 of the cup 600 also may include an upper lip 700. Theupper lip may include a substantially flat top portion 710. The flat topportion 710 may have a width of about 3.45 millimeters (about 0.136inches) and a height in the vertical direction of about 3.4 millimeters(about 0.135 inches). The lip 700 may be configured to accommodate thesize of the pod apertures 330 and the injector head 420 as well as theexpected force of the hot water provided by the injector head 420 whileusing as little material as possible. This is particularly true giventhat the cartridge 210 as a whole generally is supported only about itslip 700 during the injection process.

FIGS. 13 and 14 show an alternative embodiment of the lip 700. In thisembodiment, a lip 720 may include the substantially flat top portion 710and a downwardly angled flanged 730 that extends from the top portion730. The flange 730 may extend downward so as to form a pocket 740 withthe sidewall 610. The top of the pocket 740 may have a curved innerradius. The flange 730 and the pocket 740 of the lip 720 are sized toaccommodate the size of the pod apertures 330.

Referring again to FIGS. 6-12, the sidewall 610 of the cup 600 also mayinclude a number of cutouts 760 formed therein. In this embodiment afirst cutout 770, a second cutout 780, and a third cutout 785 may beused. Any number of cutouts 760, however, may be used. For example, onlytwo (2) cutouts 760 may be used with a 237 milliliter (about an eight(8) ounce) cup 600. The cutouts 760 may be continuous around the innercircumference of the sidewalls 610 or the cutouts 760 may beintermittent.

The cutouts 760 may cooperate with a lid 790. The lid 790 may have anedge 800 that is substantially wedge-shaped about its perimeter forinsertion within a cutout 760. The use of the cutouts 760 ensures thatthe lid 790 remains in place. The edge 800 may be continuous orintermittent so as to mate with the cutouts 760. The lid 790 preferablyis bowed inwardly or may be largely concave in shape. The lid 790 mayhave about 0.8 grams of a polypropylene material.

The lid 790 may be placed in one of the cutouts 760 depending upon theamount of brewing material that is to be placed in the cup. The lid 790may be bowed downward in a concave shape so as to tap the brewingmaterial 550 down under pressure and to keep the brewing materialtherein from shifting. The lid 790 may provide the correct tamp force tothe brewing material 550 and holds the material under load viaessentially a Bellville washer principle. The use of the lid 790 to tampthe brewing material 550 also permits a faster fill rate when loadingthe cup 600 with the brewing material 550. The lid 790 also may have anumber of apertures 810 therein so as to permit water from the injectorhead 420 to pass therethrough. Depending upon the nature of the injectorhead 420, the use of the lid 790 may not be necessary.

The cup 600 may be lined with one or more layers of a filter paper 850.The filter paper 850 may be standard filter paper used to collect thebrewing material 550 while allowing the beverage to pass therethrough.The filter paper 850, however, should have sufficient strength,stiffness, and/or porosity such that it does not deflect into theapertures 640 of the base 620 and/or allows fine particles of thebrewing material 550 to close or clog the apertures 640. Clogging theapertures 640 may create an imbalance in the pressure drop though thecartridge 210. Because of the stiff paper 850 that substantially resistsdeformation, the apertures 640 of the base 620 of the cup 600 may have asomewhat larger diameter for increased flow therethrough.

For example, the filter paper 850 may be made with a combination ofcellulose and thermoplastic fibers. Examples of suitable filter papers850 are sold by J.R. Crompton, Ltd. of Gainesville, Ga. under thedesignations PV-377 and PV 347C. For example, the PV-347C material mayhave a grammage of about forty (40) grams per square meter and a wetburst strength of about 62 kilopascals. Similar types of materials maybe used. Multiple sheets of paper also may be used. The multiple sheetseach may have the same or differing characteristics.

The pod cartridge 210 may have an upper filter layer 860 and a lowerfilter layer 870. The lower filter layer 860 is generally positionedtherein without the use of adhesives. The upper filter layer 860 may notneed as much strength as the lower layer 870. The upper filter layer 860generally provides water dispersion and prevents the grinds fromclogging the injector head 420. The brewing material 550 itself may bepositioned between the upper and lower filter layers 860, 870.Preferably, the brewing material 550 is in direct contact with thesidewall 610, i.e., there is no filter paper 850 position around theinner diameter of the cup 600. This positioning forces the water totravel through the brewing material 550 itself as opposed to travelingthrough the cup 600 via the filter paper 850.

The brewing material 550 may be placed within a foil envelope or othertype of substantially air impermeable barrier. The foil envelope 590 mayserve to keep the brewing material 550 therein fresh and out of contactwith the ambient air. Alternatively, the entire pod cartridge 210 may beplaced within a foil envelope, either individually or as a group, untilthe cartridge 210 is ready for use.

The brewable material 550 itself usually is prepared in a grinder 900.The grinder 900 may take the raw material, coffee beans in this example,and grind them into coffee grinds. As is shown in FIG. 15, the grinder900 preferably is a roller grinder. An example of such a grinder 900 ismanufactured by Modern Process Equipment, Inc. of Chicago, Ill. underthe designation of model 660FX. A roller grinder 900 is preferred overother types of grinders such as a burr grinder. The roller grinders seemto provide better particle size distribution, i.e., the particle sizedistribution is more consistent. The roller grinder 900 provides fewerlarge particles that may tend to under-extract and provide off tastesand fewer “fines” or very small coffee particles that tend to alter thetaste of the final beverage by over-extracting and contributing tobitterness. Limiting fines also has an effect on the back pressurewithin the pod cartridge 210 as the back pressure is inverselyproportional to the square of the particle size. The back pressure thusincreases as the particle size decreases.

A comparison between a roller grinder and a burr grinder is shown inFIG. 16. The roller grinder particle distribution (the “Rainforest”grind with the spike to the left) ends at about the 8.0 μm particle sizewhile the burr grinder (the “Milano” grind with the spike to the right)continues to about the 0.1 μm particle size. Likewise, there are fewerlarger particles with the roller grinder.

As is shown, over eighty percent (80%) of the grinds ground with theroller grinder 900 have a particle size distribution between about 220and about 250 microns (micrometers) with over ninety-nine percent (99%)having a particle size distribution between about eight (8) micron and650 microns. Broadly, over seventy-five percent (75%) percent of thecoffee grinds may have a particle size distribution of between about 200and about 300 microns. Although a consistent particle size distributionof around 250 microns provides an improved beverage, a certain amount offine particles also may be desired so as to provide the resistance anddesired pressure during brewing. The lack of enough fines may allow thewater to pass through too quickly. As such, ten (10) to twenty (20)percent of the distribution may be in about the forty micron range.

In order to control the number of fines and to control the back pressureand resistance, an evaluation of the particle size of the smallest tenpercent (10%) (d(0.1)) may be used. The smaller this number is, thegreater the percentage of the particles that are smaller than a givendiameter. The position of d(0.1) is shown in FIG. 17.

Generally speaking and by way of example, d(0.1) of about 43 microns maybe acceptable while 25 micron may be unacceptable.

A similar approach is to look at the surface area mean diameter. Thesurface area mean diameter is useful because as particle size decreases,the surface area to volume ratio quickly increases. The surface areamean diameter is calculated by multiplying each particle diameter by thetotal surface area of material in all particles of that size, summing,and dividing by the total surface area of all particles. Thus, for adiameter at the coordinates of 3,2 shown above, the calculation is:

${D\left\lbrack {3,2} \right\rbrack} = \frac{\sum{D_{i}^{3}n_{i}}}{\sum{D_{i}^{2}n_{i}}}$

Generally speaking and by way of example, a surface area mean diameterat D[3,2] of 116 microns may be acceptable while a diameter of 78microns may not be acceptable.

Similar calculations may be made that focus on the presence of largerparticles. For example, the volume mean diameter D[4,3] also may becalculated:

${D\left\lbrack {4,3} \right\rbrack} = \frac{\sum{D_{i}^{4}n_{i}}}{\sum{D_{i}^{3}n_{i}}}$

The roller grinder 900 thus provides a narrower and more consistentparticle size distribution. Similarly, the number of fines can bemonitored so as to limit bitterness while maintaining a consistentpressure therethrough. Such a particle size distribution provides acoffee beverage with improved and consistent taste.

The grinder 900 also may include a densifier 910. The densifier 910 mayinclude a number of blades so as to form the individual grinds into amore uniform size and shape. Specifically, the grinds seem to be have amore uniform spherical shape and seem to be somewhat hardened.Densification of the grinds results in changing the brew characteristicsin that the increase in density changes the nature of the water flowthrough the grinds.

In addition to creating substantially uniform spheres, the densifier 920also seems to reduce the number of fines or small particles by“sticking” the smaller particles to the larger particles. The stickingmay be due to the oils in the grinds, the work added to the grinds, orother causes. For example, with densification, solids in the coffee mayabout six (6) percent. Without densification, however, the solids mayreach about 7.5 percent, which provides a finished product that may betoo strong. The net result is a smaller, more uniform particle sizedistribution. Although densification has been used to improve thepacking of coffee, densification has not been employed so as to changethe brew characteristics of the grinds.

In use, the lower layer 870 of filter paper may be placed with the cup600 of the pod cartridge 210 along the base 620. An amount of thebrewing material 550 then may be positioned therein. The upper layer 860of the filter paper then may be placed on the brewing material 550 ifdesired. The lid 790 then may be placed within the cup 600 so as to tampdown the brewing material 550 with about 13.6 kilograms of force (aboutthirty (30) pounds of force). The amount of force may vary. Once the lid790 has compacted the brewing material 550, the edge 800 of the lid 790is positioned within the appropriate cutout 760 within the sidewall 610of the cup 600. The pod 210 then may be sealed or otherwise shipped foruse with the beverage dispenser system 100 or otherwise.

The pod 210 may be positioned within one of the pod apertures 330 in theturret assembly 310. Specifically, the outer edge of the pod aperture330 aligns with the lip 700 of the cup 600 such that the cup 600 issupported by the lip 700. The injector head 420 then may be positionedabout the pod 210. The sealing ring of the injector head 420 may sealabout the top portion 710 of the lip 700 of the cup 600. The use of arounded lip or a lip with a non-flat shape may cause damage to thesealing ring given the amount of pressure involved, i.e., as describedabove, the injector head 420 may engage the pod cartridge 210 with adownward force of about 136 to about 160 kilograms of force (about 300to about 350 pounds) and the incoming water flow may be pressurized atabout ten (10) to about fourteen (14) bar (about 145 to 200 pounds persquare inch (psi)). The pressure of the water flowing through podcartridge 210 may vary with the nature of the brewing material 550. Thehot pressurized water may be provided to the cartridge 210 from anysource.

The water passing through the injection head 420 may spread out over thelid 790 and the apertures 810 thereof and into the brewing material 550.The nature of the water flow through the cartridge 210 as a wholedepends in part upon the geometry and size of the cartridge 210, thenature, size, and density of the brewing material 550, the waterpressure, the water temperature, and the brew time. Altering any ofthese parameters may alter the nature of the brewed beverage. The brewedbeverage may then pass through the apertures 640 in the base 620 of thecup 600.

As is shown in FIG. 12, the pod cartridges 210 may be filled withdifferent types of grinds, leaves, or other types of a brewing material550. In the case of a single serving espresso beverage of aboutthirty-five (35) milliliters, about six (6) to about eight (8) grams ofspecially ground coffee may be placed in the pod cartridge 210.Likewise, the same amount of ground coffee may be used to brew anAmerican style coffee with the addition of about 180 milliliters (aboutsix (6) ounces) of water. About two (2) to about five (5) grams oftealeaves may be added to the pod cartridge 210 in order to brew about a180 milliliter (about six (6) ounce) cup of tea.

Each different type of coffee or other type of brewing material 550 hasa different size grind. For example, one coffee bean may be ground toabout 500 to 800 particles for a typical drip filter-type coffee. Thesame coffee bean may be ground to over 3500 particles for an espressogrind. The particles themselves have different sizes and weights.

Maintaining particle size uniformity, as described above, is preferred.Coffee grind particles that are not the correct size will generally overextract or under extract the soluble solids out of the coffee. The useof the grinder 900 helps to ensure a more consistent particle size. Theuse of the densifier 910 also assists in providing particle sizeuniformity. Tamping the coffee grinds down assists in providing uniformfluid flow through the cup 600. As described above, particle sizerelates to the back pressure that does the “work” of brewing thebeverage.

With respect to brew time and temperature, brew temperatures aretypically in the range of about 85 to about 100 degrees Celsius (about185 to about 212 degrees Fahrenheit) or sometimes warmer at about 10 toabout 14 bar. The water within the hot water reservoir 160 may be heatedto about 102 degrees Celsius (about degrees 215.6 degrees Fahrenheit) bythe heat exchanger 150. The water loses some of its heat as it passesthought the injector head 420 and into the cartridge 210.

By way of example, a “Roma” espresso beverage as described above, mayuse the 237 milliliter (eight (8) ounce) cartridge 210 with about six(6) grams of coffee grinds therein. The cartridge 210 may produce aboutthirty-five (35) milliliters of the beverage. The water may leave thehot water reservoir 160 at about 102 degrees Celsius (about degrees215.6 degrees Fahrenheit) and have a brew time of about eight (8)seconds (plus or minus two (2) seconds) at about eleven (11) bar.(Densification of the grinds may speed up the brew time and reduce theamount of extracted materials.) The 355 milliliter (twelve (12) ounce)cartridge 210 also could be used if the lid 790 is placed in a lowercutout 760. A “Dark” beverage has similar properties, but uses about 7.3grams of the grinds. As a result, the brew time is about fourteen (14)seconds.

A “Rain Forest” beverage also may use the 237 milliliter (eight (8)ounce) cartridge 210 with about six (6) grams of grinds therein. Thesegrinds, however, are coarser than the Roma grinds, such that the flowrate through the cartridge 210 may be faster. Hence the brew time wouldbe about seven (7) seconds (plus or minus two (2) seconds). A certainamount of make up water (about 180 milliliters) also may be added to thebeverage after brewing. An “Americano” beverage may use the espressogrinds described above with the various grinds and blends havingdiffering characteristic and tastes.

As is shown, the cartridge 210 also may be used to brew tea. In thisexample, about 2.8 grams of tealeaves may be used. As opposed to thetraditional method of seeping tea over several minutes, this exampleabout a 210 milliliter (about seven (7) ounce) beverage may be brewed inabout 6.2 seconds. Iced tea also may be brewed with the addition of anamount of make-up water.

Various examples of the brewing parameters are shown below:

Coffee I Coffee II Coffee III Coffee IV Tea Type Roma Dark RainforestBreakfast Chai Blend Particle 255 μm 250 μm 250 μm 255 μm size Pod size8 ounce 8 ounce 8 ounce 8 ounce 8 ounce Weight 6 grams 7.3 grams 6 grams6.75 grams 2.8 grams Density 0.378 g/ml 0.371 g/ml 0.425 g/ml 0.425 g/ml0.426 g/ml Water 102° C. 102° C. 102° C. 102° C. 102° C. temperaturePressure 11 Bar 11 Bar 11 Bar 11 Bar 11 Bar Brew time 8.0 seconds 14.0seconds 7.0 seconds 8.9 seconds 6.2 seconds Beverage 35 ml for 35 ml for210 ml for 210 ml for 210 ml size espresso; 210 ml espresso; 210 mlAmericano Americano for for Americano; Americano; Cappuccino Cappuccinohas 4 ounces has 4 ounces of of foamed foamed milk; milk; Lattes Latteshave 6 have 6 ounces ounces of hot of hot milk milk

The combination of the variables described herein thus provides a podcartridge 210 that produces a beverage with a consistent taste.Specifically, the beverage taste is consistent across the use of anynumber of cartridges 210.

Consumers also are interested in coffee and other types of beveragesthat may vary in flavor intensity and/or strength. As such, it isdesirable to offer specific beverages in low, medium, and highintensity. Such varying intensity may be possible by maintaining thesame grade or type of beans, roasting characteristics, particle sizedistribution, i.e., the same grind profile, and other types of brewingparameters, but varying the gram weight of the grinds positioned therein

In other words, a consistent type of grind may be used for a particulartype of coffee beverage. For example, the mean particle sizedistribution of a particular type of coffee may remain between about 200to about 300 microns. Specifically, about seventy-five to abouteighty-five percent (75-85%) of the coffee grinds may have a meanparticle size distribution of about 250 microns with the remainder beingfines, i.e., grinds with a particle size distribution of less than about100 microns.

Depending upon the desired intensity of the beverage, the gram weight ofthe grinds may be varied. For example, a low intensity beverage may haveabout six (6) grams of the grinds while a high intensity beverage mayhave about 7.5 grams of the grinds for a typical eight (8) ounce coffeebeverage. A medium intensity beverage would fall somewhere in between.Varying the amount of coffee also varies the brew time with morematerial requiring a longer brew time. At the specific particle sizedistribution, the pod cartridge 210 has the correct quantity of fineparticles to restrict water flow therethrough so as to provide coffeeextracts with a desired ratio of aromatics and flavor with the bittercompounds that are characteristic to coffee.

Certain grinds also are found to “bloom” at specific gram weights. Inother words, certain flavors/aroma attributes are intensified oroptimized at a particular gram weight given the mean particle size.Representative blends in all three categories of low, medium, and highflavor intensities thus may be found.

Thus, the same grinding techniques, particle size distribution, andother brewing parameters may be used for each type of coffee beveragewhile the intensity may be varied simply with varying the gram weight.The present system thus provides a vast number of beverages with varyingintensities but with highly repeatable performance. Variation on thegram weight also applies to brewable materials in addition to coffeesuch a tea leaves. Brewable, soluable, dispersible, and other types ofmaterials also may be used.

It should be apparent that the foregoing relates only to the preferredembodiments of the present application and that numerous changes andmodifications may be made herein without departing from the spirit andscope of the invention as defined by the following claims and theequivalents thereof.

We claim:
 1. A coffee pod, comprising: a substantially rigid sidewall; asubstantially rigid base; and coffee grinds positioned therein; whereinmore than about seventy percent (70%) of the coffee grinds comprise aparticle size distribution of between about 200 to about 300 microns;wherein up to about 30% of the coffee grinds comprises a particle sizedistribution of less than about 100 microns; and wherein the coffeegrinds comprise a weight of the about five (5) to about eight (8) grams.2. The coffee pod of claim 1, wherein about seventy-five to abouteighty-five percent (75-85%) of the coffee grinds may have a particlesize distribution of about 250 microns.
 3. The coffee pod of claim 1,wherein the pod comprises about eight (8) ounces for an eight (8) ouncebeverage.
 4. The coffee pod of claim 1, wherein the coffee grindscomprise about six (6) grams for a low intensity beverage.
 5. The coffeepod of claim 1, wherein the coffee grinds comprise about eight (8) gramsfor a high intensity beverage.
 6. The coffee pod of claim 1, wherein thesubstantially rigid base may withstand a pressure of about 10 to about12 bar.
 7. A brewable material pod, comprising: a substantially rigidsidewall; a substantially rigid base; and an amount of a brewablematerial positioned therein; wherein more than about seventy percent(70%) of the amount of brewable material comprises a particle sizedistribution of between about 200 to about 300 microns; wherein up toabout 30% of the amount of brewable material comprises a particle sizedistribution of less than about 100 microns; and wherein the amount ofbrewable material comprise a weight of the about five (5) to about eight(8) grams.
 8. The brewable material pod of claim 7, wherein the amountof brewable material comprises coffee grinds.
 9. The brewable materialpod of claim 7, wherein the amount of brewable material comprises tealeaves.
 10. The coffee pod of claim 1, wherein about eighty-five percent(85%) of the coffee grinds comprise a particle size distribution ofabout 250 microns and wherein about fifteen percent (15%) of the coffeegrinds comprise a particle size distribution of about 40 microns. 11.The brewable material pod of claim 7, wherein about eighty-five percent(85%) of the amount of brewable materials comprises a particle sizedistribution of about 250 microns and wherein about fifteen percent(15%) of the amount of brewable material comprises a particle sizedistribution of about 40 microns.
 12. The brewable material pod of claim7, wherein the substantially rigid base may withstand a pressure ofabout 10 to about 12 bar.